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OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
List of Supplements to Workshop Manual
OCTAVIA 1997
Edition 03.01
Supplement 1 2
Edition 03.01 04.03 12.03
Subject Basic Edition Modifications in Rep. Gr. 01 and 23 Modifications in Rep. Gr. 01 23 and 28
Article Number S00.5139.50.20 S00.5139.51.20 S00.5139.52.20
Edition 12.03 S00.5139.52.20
List of Supplements
OCTAVIA 1997
List of Supplements
Edition 12.03 S00.5139.52.20
OCTAVIA 1997
Table of Contents
01 Self-diagnosis
Self-diagnosis I ......................................................................................... 01-1 - Properties of the self-diagnosis ..................................................................... 01-1 - Technical data of self-diagnosis ..................................................................... 01-1 - Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics .............................................................................................. 01-1 - Interrogating and erasing fault memory ............................................................ 01-1 - Actuator diagnosis ..................................................................................... 01-1 Self-diagnosis II ......................................................................................... 01-2 - Fault table .............................................................................................. 01-2 Self-diagnosis III ........................................................................................ 01-3 - Readiness code ........................................................................................ 01-3 - Reading readiness code .............................................................................. 01-3 - Generating readiness code .......................................................................... 01-3 Self-diagnosis IV ....................................................................................... 01-4 - Reading measured value block ..................................................................... 01-4 - Display groups 001 to 022, engine idling .......................................................... 01-4 - ........................................................ Display groups 004 through 011 at full load 01-4 - Display group 125 - CAN databus .................................................................. 01-4 page page page page page page page page page page page page page page page 1 1 1 2 3 5 1 1 1 1 1 2 1 1 1
page 10 page 12
23 Fuel Formation, Injection

Diesel direct injection system ....................................................................... 23-1 - Safety measures ...................................................................................... 23-1 - Rules of cleanliness ................................................................................... 23-1 - Overview of fitting location ........................................................................... 23-1 - Disassembling and assembling intake manifold .................................................. 23-1 - Disassembling and assembling the air filter ....................................................... 23-1 Disassembling and assembling the unit injector ............................................... 23-2 - Summary of components ............................................................................. 23-2 Testing components ................................................................................... 23-3 - Testing lines and components with test box -V.A.G 1598/31- .................................. 23-3 - Testing unit injector valve ............................................................................ 23-3 Testing exhaust gas recirculation .................................................................. 23-4 - Connection diagram for vacuum hoses ............................................................ 23-4 - Testing exhaust gas recirculation ................................................................... 23-4 Engine control unit ..................................................................................... 23-5 - Testing voltage supply for engine control unit .................................................... 23-5 - Replacing diesel direct injection system control unit -J248- .................................... 23-5 - Coding diesel direct injection system control unit -J248- ........................................ 23-5 - Activating and deactivating cruise control system (CCS) ....................................... 23-5 Testing auxiliary signals .............................................................................. 23-6 - Testing CAN databus ................................................................................. 23-6 - Testing the speed signal ............................................................................. 23-6 page page page page page page page page page page page page page page page page page page page page page page 1 1 1 2 5 6 1 1 1 1 1 1 1 1 1 1 2 3 4 1 1 2
28 Glow Plug System
Edition 12.03 S00.5139.52.20
Table of Contents
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System page page page 1 1 2
Testing preheating system ........................................................................... 28-1 - Check for proper operation .......................................................................... 28-1 - Checking glow plugs .................................................................................. 28-1
II
Table of Contents
Edition 12.03 S00.5139.52.20
OCTAVIA 1997
01
01 Self-diagnosis
01-1 Self-diagnosis I
Properties of the self-diagnosis

The control unit for the diesel direct injection system is equipped with a fault memory. The fault memory is designed as a permanent memory. If malfunctions occur in the monitored sensors or components, they are stored in the fault memory with indication of the fault type. Fault table Chap. 01-2. Faults which occur only temporarily (sporadically) are displayed with the suffix /SP. Possible causes of sporadic faults are e.g. a loose contact or a momentary line interruption. If a sporadic fault no longer occurs after 50 engine starts, it is automatically erased. If faults are detected that are likely to influence the driving behaviour, the glow period warning lamp -K29- flashes. The stored faults can be read out with the vehicle system tester -V.A.G 1552-, -V.A.G 1551- or -VAS 5051 01-1 page 2. After the fault(s) has(have) been removed the fault memory must be erased 01-1 page 3. Note The following description only relates to vehicle system tester -V.A.G 1552- using the current program card. When not using the current program card or when using the fault read-out scan tool -V.A.G 1551- with integrated printer or using the vehicle diagnosis, measurement and information system -VAS 5051- a minor deviation in the display is possible.
Technical data of self-diagnosis

Interrogating control unit version
The control unit version is displayed once the vehicle system tester -V.A.G 1552 - is connected and the engine electronics control unit is selected 01-1 page 2.
Available functions when using the vehicle system tester -V.A.G 1552The preconditions for selecting the desired functions are given in the following table.
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Condition Operation 01 02 03 04 05 06 07 08 11
1)
Engine not running, ignition switched on yes yes1) yes no yes yes yes yes yes
Engine idling yes yes yes yes yes yes no yes no
Normal driving yes yes no no yes yes no yes no
Interrogating control unit version Interrogating fault memory Actuator diagnosis Basic setting Erasing fault memory Ending output Coding control unit Reading measured value block Login procedure
Only perform with the ignition on, if the engine does not start.
Connecting vehicle system tester -V.A.G 1552- and selecting the control unit for engine electronics
Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Battery voltage at least 11.5 volts Earth connection to engine and gearbox O.K. Fuses must be OK in compliance with the current flow
diagram.
Procedure
1 4
2 5 7
3 6 8 C O 9 Q
HELP
V.A.G.1552
Connect vehicle system tester - V.A.G 1552- with cable. Once the vehicle system tester has been connected:
V.A.G 1552 V.A.G 1551/3
Switch on ignition or start 01-1 page 1 engine depending on the function desired. Note If data transfer errors are displayed as a result of an incorrect entry, disconnect cable at vehicle system tester, connect it in again and repeat all the steps. If one of the following messages appears in the display, test the diagnostic cable Current Flow Diagrams, Electrical Fault Finding and Fitting Locations or Operating Instructions of vehicle system tester.
Vehicle system test The control unit does not respond
S01-0045
HELP
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01
HELP
Vehicle system test Fault in communication set-up Vehicle system test K cable does not connect to earth
HELP
Operate the vehicle system tester by referring to the

read-out on the display. Readout on display:
Vehicle system test HELP K cable does not connect to pos. term.
Vehicle system test Enter address word XX
HELP
Enter address word 01 Engine electronics and confirm entry with

Q. 038906019R 1.9l R4 Coding 00003 EDC G000SG 1053 -> WSC XXXXX
The control unit identification appears in the display, e.g.: 038906019R = Part No. of control unit (for current control unit version refer to Parts List) 1.9 ltr. = engine displacement R4 = engine version (4 cyl. in-line engine) EDC = Injection system (Electronic Diesel Control) CC = Cruise control system activated (only on models with CCS) 000 = Control unit ID MG = Manual gearbox 1053 = Data status (Software version of the control unit) Coding 00003 = Coding version of control unit WSC XXXXX = Workshop identification Note If the control unit version displayed does not correspond to the vehicle, replace the control unit Chapter 23-5. Incorrect coding of the engine control unit results in: Handling problems (jerky gear change, load change jolts etc.) Increase in fuel consumption Increase in pollution Storage of non-existent faults in fault memory
Interrogating and erasing fault memory

Interrogating fault memory
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
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Only if the engine does not start:
Switch on ignition. Enter function 02 Interrogate fault memory and confirm entry with the Q key. The number of stored faults or No fault recognised appears in the display. If no fault is stored:
X faults detected!
Enter function 06 End output and confirm entry with

Q.
If one or several faults are stored:
Press
. -> Fault number: 16685 P0301 044
Readout on display, e.g.:
Press
. Cylinder 1 Combustion misfiring detected ->
Fault source and fault type appear in the display, e.g.:
Press
The stored faults are displayed in sequence.

Q.
Rectify the faults displayed by referring to the fault table Chapter 01-2. Note When carrying out testing and removal and installation operations faults such as connector unplugged or CAN bus faults, may also be detected by other control units. This is why, when the work is concluded, that it is necessary to interrogate and erase the fault memory on all control units. For this you must proceed as follows:
Enter function 00 for Automatic test sequence and

confirm with
Q.
The Vehicle system tester -V.A.G 1552- sends all the known address words one after the other.
Erasing fault memory

Test conditions
Fault eliminated Fault memory interrogated 01-1 page 3

Note After fault elimination the fault memory must again be interrogated and subsequently erased.
Enter function 05 Erase fault memory and confirm

entry with the Q key. Readout on display:
Vehicle system test Fault memory was erased ->
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Self-diagnosis I
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Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.

Q.
Perform a test drive. Then, once again interrogate the

fault memory. No fault must be displayed.
Actuator diagnosis
With the actuator diagnosis the following parts are activated in the sequence indicated: 1 - Exhaust gas recirculation valve -N182 - AC compressor engagement 3 - Solenoid valve for charge pressure control -N754 - Changeover valve for intake manifold flap -N2395 - Glow period warning lamp -K296 - Radiator fan control 7 - Glow plug relay -J528 - Low heat output relay -J3599 - High heat output relay -J36010 - Fault lamp Note Actuation of the individual control elements is limited to 30 seconds. If final control diagnosis is to be repeated wirthout starting the engine in-between, switch ignition off for about 20 seconds. Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Test conditions
Fuses must be OK in compliance with the current flow

diagram.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics 01-1 page 2.
Enter function 03 Final control diagnosis.
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01
Readout on display: The valve must click. Note
OCTAVIA 1997
Actuator diagnosis Exhaust gas recirculation valve -N18
->
The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Testing Exhaust gas recirculation valve -N18 Chap. 23-1.

. Actuator diagnosis AC compressor engagement ->
Press
Readout on display: This test step is also activated on vehicles without AC system.
Disregard display. Press

. Actuator diagnosis -> Charge press.control solenoid valve -N75
Readout on display: The valve must click. Note The clicking of the valve cannot be heard because of the engine noise and can therefore only be checked. If the valve does not click:
Test charge pressure control solenoid valve -N75 Chap. 23-1.

. Actuator diagnosis -> Intake manif.flap change-over valve-N239
Press
Readout on display: The engine must stop. If the engine does not stop:
Switch off ignition. Inspecting Intake manifold flap change-over valve

-N239- Chap. 23-1.
Continue final control diagnosis with the engine off

and the ignition switched on.
Press
. Actuator diagnosis Glow period warning lamp -K29 ->
Readout on display: The warning light for glow period must flash. If the warning light does not flash:
Test glow period warning light - K29 - Electrical

System; Rep. Gr. 90.
Press
. Actuator diagnosis Radiator fan control ->
Readout on display: Radiator fan control unit -J293- switches the radiator fan on and off for 30 seconds.
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Self-diagnosis I
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01
If the fan does not run:
Testing radiator fan -V7- and radiator fan control unit

-J293- Current Flow Diagrams, Fault Finding Electrics and Fitting Locations.
. Actuator diagnosis Glow plug relay -J52 ->
Press
Readout on display: The relay must click. It is also possible to observe the relay switching on and off by the interior light becoming brighter and darker (caused by the high power consumption of glow plugs). If the relay does not click:
Test glow plug relay -J52- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis Low heat output relay -J359 ->
Readout on display: The relay must click. If the relay does not click:
Test low heat output relay -J359- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis High heat output relay -> -J360
Readout on display: The relay must click. If the relay does not click:
Test high heat output relay -J360 - Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Press
. Actuator diagnosis Fault lamp ->
Readout on display: The fault lamp must flash. If the fault lamp does not flash:
Test fault lamp Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations.
Press
. Vehicle system test Select function XX HELP
Readout on display:

Q.
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Self-diagnosis I
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01-2
Self-diagnosis II
Fault table
Note The fault table is ordered according to the 5-digit fault code on the left. The SAE code which is displayed on the right next to the fault code (e.g. P0107) can be ignored (at present only valid for USA). Explanations regarding fault types (e.g. open circuit or short-circuit to earth) Operating instructions for the vehicle system tester. If parts are output as faulty: First of all test all leads and plug connections to these components, as well as the earth connections according to current flow diagram. Only if no fault is detected here should the part be replaced. This applies in particular if faults are shown as sporadic (SP). If Info in literature appears in the display of the vehicle system tester - V.A.G 1552- look for the text required in the fault table under the fault code. Readout on -V.A.G 155216485 Air mass meter -G70 16684 Combustion misfiring detected 16685 Cyl. 1 combustion misfirings detected 16686 Cyl. 2 combustion misfirings detected 16687 Cyl. 3 combustion misfirings detected 16688 Cyl. 4 combustion misfirings detected Implausible sig16705 Engine speed sender - nal G28 16706 No signal Engine speed sender G28 Implausible signal Rectifying fault
Test air mass meter -G70 - Chap. 01-4, display group 003 Test compression 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15.
Check unit injector Chap. 23-3
Inspecting Engine speed sender -G28- Chap. 23-1 Inspecting Engine speed sender -G28- Chap. 23-1 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit -J248- Chap.

23-5 16725 Camshaft pos. sensor => Sender -G40 Implausible signal
Test camshaft position sensor -G40- Current Flow Diagrams,

Electrical Fault Finding and Fitting Locations
Remove open circuit in wiring or short circuit according to current
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test position of camshaft and sensor rotor 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15. 16885 Vehicle speed signal Implausible signal
Test vehicle speed signal Chapter 23-6
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Readout on -V.A.G 155216944 Voltage supply 16946 Voltage supply 16947 Voltage supply 16955 Brake light switch -F 16989 Control unit defective 17552 Air mass meter -G70 17553 Air mass meter -G70 17554 Air mass meter -G70 17563 Intake manifold pressure sender -G71 17564 Intake manifold pressure sender -G71 17565 Intake manifold pressure sender -G71 17568 Intake manifold temperature sender -G72 17569 Intake manifold temperature sender -G72 17570 Fuel temperature sender -G81 17571 Fuel temperature sender -G81 17663 Coolant temperature sender -G62 17664 Coolant temperature sender -G62
OCTAVIA 1997
Rectifying fault
Implausible signal Voltage too low Voltage too high Implausible signal
Test cables to diesel direct injection system control unit - J248- ac-
cording to the current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Test brake light switch - F- and brake pedal switch -F47- Chap.
01-4, display group 006
Replace diesel direct injection system control unit -J248 - Chap.

23-5 Open circuit or short circuit to earth Short circuit to positive Voltage supply Short circuit to positive Open circuit or short circuit to earth Voltage supply
Test air mass meter -G70- Chap. 01-4, display group 003 Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations

23-5
Test intake manifold pressure sender -G71- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Check wiring according to current flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Replace diesel direct injection system control unit - J248 - Chap.

23-5
Test intake manifold pressure Chap. 01-4, display group 010 Test intake manifold temperature sender -G72- Chap. 01-4, display group 007
Short circuit to earth Open circuit/ Short circuit to positive Short circuit to earth Open circuit/ Short circuit to positive

23-5
Test fuel temperature sender -G81- Chap. 01-4, display group

007
Replace diesel direct injection system control unit - J248 - Chap.

23-5
Short circuit to earth
Test coolant temperature sender -G62- Chap. 01-4, display group

007

23-5
01-2 page 2
Self-diagnosis II
Edition 12.03 S00.5139.52.20
OCTAVIA 1997
1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System Rectifying fault
01
Readout on -V.A.G 155217668 Unit injector solenoid valve cyl. 1 -N240 17669 Unit injector solenoid valve cyl. 1 -N240 17670 Unit injector solenoid valve cyl. 1 -N240 17671 Unit injector solenoid valve cyl. 2 -N241 17672 Unit injector solenoid valve cyl. 2 -N241 17673 Unit injector solenoid valve cyl. 2 -N241 17674 Unit injector solenoid valve cyl. 3 -N242 17675 Unit injector solenoid valve cyl. 3 -N242 17676 Unit injector solenoid valve cyl. 3 -N242 17677 Unit injector solenoid valve cyl. 4 -N243 17678 Unit injector solenoid valve cyl. 4 -N243 17679 Unit injector solenoid valve cyl. 4 -N243 17795 Control unit defective 17810 Exhaust gas recirculation valve -N18 17849 Exhaust gas recirculation valve -N18 17910 Fuel pump relay -J17 17911 Load signal for alternator terminal DF Short circuit to positive Open circuit or short circuit to earth Short circuit to positive Implausible signal Implausible signal Regulating limit exceeded Regulating limit not reached
Check unit injector Chap. 23-3 Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 20
Implausible signal Regulating limit exceeded Regulating limit not reached

23-5
Test exhaust gas recirculation valve -N18- with final control diagnosis Chap. 01-1
Inspecting exhaust gas recirculation Chap. 23-4
Testing fuel pump relay -J17- Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations
Test generator Current Flow Diagrams, Electrical Fault Finding

and Fitting Locations and Electrical System; Rep. Gr. 27
Reading measured value block, display group 016 Chap. 01-4
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Self-diagnosis II
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01
Readout on -V.A.G 155217931 Crash signal from airbag CU 17932 Fuel pump relay -J17 17948 Vehicle speed signal
OCTAVIA 1997
Rectifying fault
Implausible signal Open circuit or short circuit to earth Signal too high
Test airbag system Body Work; Rep. Gr. 01 Testing fuel pump relay -J17- Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
17954 Charge pressure control solenoid valve N75 17957 Charge pressure control solenoid valve N75 17958 Charge pressure 17964 Charge pressure control 17965 Charge pressure control 17977 Cruise control system switch -E45
Short circuit to positive
Test vehicle speed signal Chapter 23-6 Test CAN databus lines Chapter 23-6 Test dash panel insert Electrical System; Rep. Gr. 90 Test charge pressure control solenoid valve -N75- with final control diagnosis Chap. 01-1
Open circuit or short circuit to earth Control difference Regulating limit not reached Regulating limit exceeded Implausible signal
Test charge pressure control solenoid valve - N75- with final control
diagnosis Chap. 01-1
Reading measured value block, display group 010 Chap. 01-4 Test charge pressure control 1.9/74 kW (TDI) Engine, Mechanical
Components; Rep. Gr. 21
Analyse measured value block, display groups 006 and 022

Chap. 01-4
Read out fault memory of the electrical system control unit

Electrical System; Rep. Gr. 90
17978 Engine control unit blocked1) 18008 Voltage supply terminal 15 18009 Voltage supply relay terminal 30 -J3172) 18017 Crash disconnect activated 18020 Engine control unit 18024 Glow period warning lamp -K29 18025 Glow period warning lamp -K29 Incorrectly coded Short circuit to positive Open circuit or short circuit to earth Voltage too low
Adapt diesel direct injection system control unit - J248- to electronic

immobiliser Electrical System; Rep. Gr. 96
Test immobiliser Electrical System; Rep. Gr. 96 Test voltage supply for diesel direct injection system control unit
-J248- Chap. 23-5
Implausible signal
Test diesel direct injection system relay -J322- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
Read out fault memory of airbag control unit Body Work;

Rep. Gr. 01
Replace airbag control unit Body Work; Rep. Gr. 69 Code diesel direct injection system control unit -J248- Chap. 23-5 Test glow period warning lamp -K29- with final control diagnosis
Chap. 01-1
01-2 page 4
Self-diagnosis II
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01
Readout on -V.A.G 155218026 Glow plug relay -J52 18027 Glow plug relay -J52 18039 Accelerator pedal position sender -G79 18040 Accelerator pedal position sender -G79 18043 Data BUS drive Short circuit to positive Short circuit to earth Signal too high
Test glow plug relay -J52 - with final control diagnosis Chap. 01-1
Test accelerator pedal position sender -G79- Chap. 01-4, display

group 002
Voltage supply
Missing message from air conditioning system CU Missing message from airbag CU missing message form electron. CU
Test CAN databus lines Chapter 23-6 Read out air conditioning system control unit fault memory
Heating, Air conditioning; Rep. Gr. 01
18044 Data BUS drive 18045 Data BUS drive
Test CAN databus lines Chapter 23-6 Read out fault memory of airbag CU Body Work; Rep. Gr. 01 Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
18047 Implausible sig1/2 for accelerator nal pedal position sender G79+G185 18048 Control unit defective 18056 Data BUS drive 18057 Data BUS drive 18058 Data BUS drive defective
Test accelerator pedal position sender -G79- Chap. 01-4, display

group 002

23-5

23-5
Missing message from ABS CU Missing message from combiinstrument
Test CAN databus lines Chapter 23-6 Read out fault memory of engine CU Chapter 01-1 Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Chassis; Rep. Gr. 45
Test CAN databus lines Chapter 23-6 Read out fault memory of dash panel insert Electrical System;
Rep. Gr. 90
18062 Read out fault memory of combiinstrument 18065 Air conditioning system inlet/outlet 18067 Radiator fan control 1 18071 Actuation of unit injector solenoid valve 18072 Actuation of unit injector solenoid valve 18073 Actuation of unit injector solenoid valve Short circuit to positive Electrical fault in the circuit Mechanical fault Short circuit to positive
Perform self-diagnosis of the dash panel insert Electrical System;

Rep. Gr. 01
Test AC compressor control with final control diagnosis Chap. 011
Test radiator fan control with final control diagnosis Chap. 01-1 Check unit injector Chap. 23-3
Replacing unit injector Chap. 23-2
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Self-diagnosis II
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01
Readout on -V.A.G 155218074 Unit injector solenoid valve cyl. 1 -N240 18075 Unit injector solenoid valve cyl. 2 -N241 18076 Unit injector solenoid valve cyl. 3 -N242 18077 Unit injector solenoid valve cyl. 4 -N243 18080 Radiator fan control 1 18090 Data BUS drive 18097 Data BUS drive
OCTAVIA 1997
Rectifying fault
Electrical fault in the circuit
Test unit injector Chap. 23-3
Open circuit or short circuit to earth implausible message from ABS CU Implausible message from electron. CU Missing message from combiinstrument Implausible signal
Test actuation of radiator fan -V7- with final control diagnosis

Chap. 01-1
Test CAN databus lines Chapter 23-6 Read out fault memory of ABS control unit Chassis; Rep. Gr. 45 Test CAN databus lines Chapter 23-6 Read out fault memory of electrical system control unit Electrical
System; Rep. Gr. 90
19456 Glow period warning lamp -K2919458 Kick-down switch -F8-
Test CAN databus lines Chapter 23-6 Test accelerator pedal position sender -G79- Chap. 01-4, display
group 002
Short circuit to 19459 Low heat output relay - positive J359 19461 High heat output relay -J360 19463 Camshaft pos. sensor => Sender -G40 No signal
Test low heat output relay -J359- with final control diagnosis
Chap. 01-1
Test high heat output relay -J360- with final control diagnosis
Chap. 01-1

Test position of camshaft and sensor rotor 1.9/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 15. Signal outside tolerance
19464 Camshaft pos. sensor => Sender -G40

Remove open circuit in wiring or short circuit according to current
flow diagram Current Flow Diagrams, Electrical Fault Finding and Fitting Locations gine, Mechanical Components; Rep. Gr. 15.
Test position of camshaft and sensor rotor 1.9/74 kW (TDI) En-
01-2 page 6
Self-diagnosis II
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OCTAVIA 1997
01
Readout on -V.A.G 155219560 Intake manifold flap change-over valve N239 19561 Intake manifold flap change-over valve N239 19586 Exhaust gas recirculation system 19587 Exhaust gas recirculation system
1)
Short circuit to positive
Test intake manifold flap changeover valve -N239- with final control
diagnosis Chap. 01-1
Open circuit or short circuit to earth Regulating limit not reached Regulating limit exceeded
Testing Exhaust gas recirculation valve -N18- Chap. 23-1 Inspecting exhaust gas recirculation Chap. 23-4
2)
When attempting to start with a non-adapted key a static fault is stored in the memory. If a subsequent start attempt occurs with an adpated key the fault is changed to a sporadic fault. Relay for voltage supply terminal 30 -J317- is identical with relay for diesel direct injection system -J322-.
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Self-diagnosis II
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01-3
Self-diagnosis III
Readiness code Reading readiness code

Operation The readiness codes are two eight-digit numerical codes which indicate the status of the emission-relevant diagnoses. If the diagnosis for a system was successfully performed (e.g. exhaust gas recirculation system), the relevant position of the numerical code is set from 1 to 0. This diagnosis is performed at regular intervals during normal driving. If repairs have been done on a system relevant for the exhaust gas it is recommended to generate the readiness code as this guarantees that the systems operate according to the specifications. If a fault is detected during the diagnosis it is entered in the fault memory. Readiness code is erased, i.e all relevant points will be set to 1, through deletion of the fault memory. Generation of readiness code refers to the activation of the diagnostic functions such as diagnosis of fuel supply, diagnosis of other systems etc. Procedure Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Connect vehicle system tester -V.A.G 1552- and enter

address word 01 Engine electronics Chap. 01-1.
Select function 08 Read measured value block and

display group number 017. Readout on display:
Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Meaning of 8-digit numerical block for readiness code in display field 2 1 2 3 4 5 6 7 1 1 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Diagnosis of other systems Diagnosis of fuel system Ignore Meaning
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Meaning of 8-digit numerical block for readiness code in display field 4 1 2 3 4 5 6 7 0 0 0 0 0 0 0 8 0 Ignore Ignore Ignore Ignore Ignore Ignore Ignore Diagnosis of exhaust gas recirculation system Meaning
If the specified values are not reached, generate readiness code 01-3 page 2.
Press key. Select function 06 End output and switch ignition off.
Generating readiness code

Test conditions
All electrical consumers such as lights and rear window heater switched off
Intake air temperature must be below 60C display

group 007, display field 3
Coolant temperature at least 83C display group

007, display block 4
Procedure
Connect vehicle system tester -V.A.G 1552-. Select
address word 01 Engine electronics Chapter 011. Note
Certain work steps have to be carried out twice, in order to achieve the readiness code.
Work step 1: Interrogating fault memory
Enter function
0 2 Interrogate fault memory and confirm entry with Q . X faults detected
The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
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Rectify the faults by referring to the fault table

Chapter 01-2. If no fault is stored:
Press
Work step 2: Erasing fault memory
Select function
0 5 Erase fault memory and con-
firm entry with Q . Note Readiness code is erased each time the fault memory is erased. Readout on display: Note If the ignition is switched off during Interrogating fault memory and Erasing fault memory, the fault memory is not erased.
Vehicle system test The fault memory is erased ->
Press
Work step 3: Switch off ignition
Wait at least 5 seconds with ignition switched off.

Note This point is important, because for certain diagnoses the castor of the control unit must be ended. Otherwise the readiness code cannot be generated.
Work step 4: Switch on ignition
Wait at least 10 seconds with ignition switched on.

Charge pressure sender is adapted to atmospheric pressure sender.
Work step 5: 1. Test of fuel system and other systems
Start engine. Select function

0 8 Read measured value block
and display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed. Readout on display:
Reading measured value block 2500 rpm 4.6 mg/s 2 0CA 1 -> 94.2 C
Work step 6: 1. Test of exhaust gas recirculation
Increase engine speed to 1600 rpm up to 1700 rpm

and maintain it for at least 10 seconds in this range.
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Readout on display:
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In this speed range, the exhaust gas recirculation is active and the control difference is checked. (Condition for generation of readiness code for exhaust gas recirculation).
Reading measured value block 1650 rpm 4.1 mg/s 4 0CA
1 -> 93.2 C
Work step 7: Switch off ignition
Wait at least 5 seconds with ignition switched off.

Work step 8: Switch on ignition
Wait at least 10 seconds with ignition switched on.

Work step 9: 2. Test of fuel system and other systems
Start engine. Select function

0 8 Read measured value block and display group 001.
Increase engine speed for 5 seconds to 2500 rpm and

then run engine at idling speed. Readout on display:
Work step 10: 2. Test of exhaust gas recirculation
Increase engine speed to 1600 rpm up to 1700 rpm

and maintain it for at least 10 seconds in this range. Readout on display:
Press Enter
C. 0 1 7 for display group 017 and read readiReading measured value block 00000000 00000110 10000000 17 -> 00000000
ness code. Readout on display: Specification in display field 2: 00000110 Specification in display field 4: 00000000
Press . If the specified values are not reached, repeat procedure for generating readiness code 01-3 page 2.
Work step 11: Interrogating fault memory
Enter function
0 2 Interrogate fault memory and X faults detected
confirm entry with Q . The number of stored faults or No fault recognised appears in the display. If a fault is stored in the memory:
Rectify the faults by referring to the fault table
Chapter 01-2 and generate readiness code again 01-3 page 2.
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Press
. Reading measured value block 00000000 00000110 10000000 17 -> 00000000
Readiness code was successfully generated, if no fault is stored after repeating the test procedure in the fault memory of the engine control unit and if the following appears in the channel 017.
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01-4
Self-diagnosis IV
Reading measured value block

Test conditions
Coolant temperature must be at least 75 C. All electrical consumers, e.g. lights and rear window
heater, must be switched off.
If vehicle is equipped with air conditioning, this must

be switched off.
Procedure
Connect vehicle system tester -V.A.G 1552-. Start engine and select the address word 01 Engine electronics Chapter 01-1.
Enter function 08 Read measured value block and

confirm entry with Q .
Enter display group 01-4 page 1.
Display groups 001 to 022, engine idling

Display group 001 in idle (engine warm, coolant temperature not below 75 C)
Read measured value block 1 xxx rpm 1 xx.x mg/s 2 x.xx KW 3 xxx.x C 4 < Display field Coolant temperature Fuel delivery duration (set value) Injection rate Engine speed Specification 75,0110.0 C 5...8 KW 3,09.0 mg/s 800950 rpm Analysis ---- 01-4 page 1 --< Readout on display
Analysis: Display group 001, display field 2 - Injection rate
Readout on -V.A.G 1552below 3.0 mg/s above 9.0 mg/s
Rectifying fault
Check unit injector Chap. 23-3. Warm up engine by running at high revs and repeat test. Check unit injector Chap. 23-3.
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Read measured value block 2 xxx rpm 1 xxx.x % 2 xxx 3 xxx.x C 4 < Display field Coolant temperature Operating position Accelerator pedal position Engine speed Specification 75,0110.0 C 010 0,0 % 800950 rpm Analysis -- 01-4 page 2 01-4 page 2 --< Readout on display
Analysis: Display group 002, display field 2 - Accelerator pedal position
Readout on -V.A.G 15521100,0 %
Rectifying fault
Test accelerator pedal position sender -G79- Current Flow Diagrams,

Analysis: Display group 002, display field 3 - Operating position

Meaning, if display positions = 1 X X 1 1 X 1 Operating position Air conditioning switched on Idling switch closed (accelerator pedal not pressed) Ignore
Read measured value block 3 xxx rpm 1 xxx mg/s 2 xxx mg/s 3 xxx % 4 < Display field On/off ratio (actuation) of exhaust gas recirculation valve drawn in air mass (actual value) drawn in air mass (nominal value) Engine speed Specification 5070 % Analysis --< Readout on display
210...370 mg/s 230...350 mg/s 800950 rpm
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Analysis: Display group 003, display field 2 - inducted air mass (set value)
Readout on -V.A.G 1552above 350 mg/s
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 003, display field 3 - inducted air mass (actual value)
Readout on -V.A.G 1552below 210 mg/s
Rectifying fault
above 370 mg/s
Test exhaust gas recirculation Chap. 23-4. Test intake system for leaks. Warm up engine by running at high revs and repeat test. Engine idles for too long, briefly blip throttle. Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3 xx.x KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -5+4 KW 3,07.0 KW 4 BTDC1 ATDC 800950 rpm Analysis 01-4 page 3 -- 01-4 page 3 --< Readout on display
Analysis: Display group 004, display field 2 - commencement of injection (set value)
Readout on -V.A.G 1552less than 4 BTDC
Rectifying fault
Engine too cold, warm up engine by running at high revs and repeat test.
Analysis: Display group 004, display field 4 - Synchronizing angle
Readout on -V.A.G 1552above 4 KW or under -5 KW
Rectifying fault
Test camshaft position sensor -G40- Current Flow Diagrams, Electrical

Fault Finding and Fitting Locations.
Check position of camshaft and sensor rotor 1.9/74 (TDI) Engine, Mechanical Components; Rep. Gr. 15.
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Read measured value block 6 xxx km/h 1 xxx 2 xx.x % 3 xxx 4 < Display field Operating state of cruise control Accelerator pedal position Status of the brake and clutch pedal switch Vehicle speed Specification xxx 0% 000 0 km/h Analysis 01-4 page 4 01-4 page 2 01-4 page 4 --< Readout on display
Analysis: Display group 006, display field 2 Status of brake and clutch pedal switch
Meaning, if display positions = 1 X X X 1 1 1 Operating position Brake light switch -F- closed (brake pedal operated) Brake pedal switch -F47- opened (brake pedal operated) Clutch pedal switch -F36- opened (clutch pedal operated)
Analysis: Display group 006, display field 4 - Operating condition of cruise control
Display 0 1 255 Operating position Vehicle with cruise control system, cruise control system switched off Vehicle with cruise control system, cruise control system switched on Vehicle without cruise control system, or cruise control system function in engine control unit not activated
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Display group 007 with ignition switched on (engine cool and standing)
Read measured value block 7 xxx.x C 1 xxx % 2 xxx.x C 3 xxx.x C 4 < Display field Coolant temperature Intake manifold temperature Status of the fuel cooling Fuel temperature
1)
< Readout on display
Specification approx. ambient temperature 1) approx. ambient temperature 1) 0% approx. ambient temperature 1)
Analysis 01-4 page 5 01-4 page 5 -- 01-4 page 5
It is not possible to give a nominal value indication for temperatures. Once the engine has cooled down the temperatures of the fuel, intake manifold and coolant must approximately correspond with the ambient temperature. If there is a marked value difference check the relevant sender.
Analysis: Display group 007, display field 1 - Fuel temperature
Readout on -V.A.G 1552-5.4 C
Rectifying fault
Inspecting Fuel temperature sender -G81- Chap. 23-1.
Analysis: Display group 007, display field 3 - Intake manifold temperature
Readout on -V.A.G 1552approx. 134.9 C
Rectifying fault
Inspecting Intake manifold temperature sender -G72 - Chap. 23-1.
Analysis: Display group 007, display field 4 - Coolant temperature
Readout on -V.A.G 1552great deviation from ambient temperature
Rectifying fault
Inspecting coolant temperature sender -G62- Chap. 23-1.

In the event of a fault the fuel temperature is displayed instead.
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Read measured value block 10 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field Accelerator pedal position Charge pressure (actual value) Atmospheric pressure drawn in air mass (actual value) Specification 0,0 % 900...1150 mbar 900...1100 mbar 210...370 mg/s Analysis 01-4 page 2 ---- 01-4 page 3 < Readout on display
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 20...50 % Analysis --< Readout on display
900...1150 mbar 900...1100 mbar 800950 rpm
-------
Read measured value block 13 x.xx mg/s 1 x.xx mg/s 2 x.xx mg/s 3 x.xx mg/s 4 < Display field Smooth running control injected quantity cylinder 4 Smooth running control - injected quantity cylinder 3 Smooth running control - injected quantity cylinder 2 Smooth running control - injected quantity cylinder 1 Specification -2,80+2.80 mg/s Analysis 01-4 page 7 01-4 page 7 01-4 page 7 01-4 page 7 < Readout on display
-2,80+2.80 mg/s -2,80+2.80 mg/s -2,80+2.80 mg/s
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Analysis: Display group 013, display field 1 to 4 - idle smooth running control
The injection system has an idle smoothness regulator. It is possible to detect differences in performance between individual cylinders (part tolerances, injector flow, compression etc.) and to compensate for these by selectively metering the quantity injected in the idling speed range. Differences are detected in the idling speed range on the basis of the signal supplied by the engine speed sender which supplies four signals to the control unit for each crankshaft revolution. If the signals have the same rhythm, the cylinder have the same output. If a cylinder has a lower output, the crankshaft will need more time for the next half crankshaft rotation. As opposed to this a high output cylinder will accelerate the crankshaft to such an extent that it will need less time. Once the control unit has identified a deviation, the relevant cylinder will immediately be supplied with a greater or smaller injection rate until the engine again runs smoothly. + mg/s: The relevant cylinder has less output and is therefore supplied with more fuel. - mg/s: The relevant cylinder has more output and is therefore supplied with less fuel.
Display group 016 in idle

Read measured value block 16 xxx % 1 xxxxxxxx 2 xx 3 xx.x V 4 < Display field Supply voltage of the engine control unit Heating element control Auxiliary heating Generator capacity Specification 13,514.5 V xx 1x00001 595 % Analysis 01-4 page 8 01-4 page 8 01-4 page 7 ---
Analysis: Display group 016, display field 2 - Auxiliary heating
Meaning, if display positions = 1 X X X X X X X X 1 1 1 1 1 Additional heating deactivated, because: Coolant temperature greater than 7075 C or intake air temperature greater than +5C Generator defective Battery voltage below 9 V Engine speed less than 800 rpm Engine start within the last 10 seconds
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Meaning, if display positions = 1 X X X 1 1 1 X X X X X Additional heating deactivated, because: Coolant temperature sender -G62 - or Intake manifold temperature sender -G72 - defective Ignore Ignore
Analysis: Display group 016, display field 3 Control of the heating elements
Meaning, if display positions = 1 X 1 X 1 Operating position Low heat output relay -J359- switched on High heat output relay -J360- switched on
Analysis: Display group 016, display field 4 - supply voltage of engine control unit
Readout on -V.A.G 1552less than 13.5 V Rep. Gr. 27.
Rectifying fault
Test generator and battery voltage, charge battery Electrical System; Increase engine speed slightly for a few minutes and switch off additional
consumers.
greater than 14.5 V
Test supply voltage of engine control unit Chap. 23-5. Rectify any current drain. Test voltage regulator, replace if necessary Electrical System; Rep. Gr.
27.
Remove start aid cable or quick charger.
Display group 018 in idle

Read measured value block 18 xx 1 xx 2 xx 3 xx 4 < Display field Unit injector cyl. 4 Unit injector cyl. 3 Unit injector cyl. 2 Unit injector cyl. 1 Specification 0 0 0 0 Analysis 01-4 page 9 01-4 page 9 01-4 page 9 01-4 page 9
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Analysis: Display group 018, display field 1 through 4 - Display of the conditon of the unit injectors
Readout on -V.A.G 1552If number instead of zero
Rectifying fault
Check unit injector Chap. 23-3. Test fuel supply 1.9/74 kW (TDI) Engine, Mechanical Components;
Rep. Gr. 20.
Display group 022, engine idling

Read measured value block 22 x 1 xxxxxx 2 x 3 x 4 < Display field Operating state of air conditioning Operating state of charge pressure control Operating state of cruise control Operating condition of the cruise control system Specification 0 0 xxxxxx x Analysis 01-4 page 10 01-4 page 9
Analysis: Display group 022, display field 1 - operating state of cruise control system
Operating condition of the cruise control system 1 9 0 Vehicle with CCS - CCS switched off Vehicle with CCS - CCS switched on Vehicle without CCS, or CCS function in engine control unit not activated
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Analysis: Display group 022, display field 2 - operating state of cruise control system
A
Cruise control Switch B on ON Switch B on RES Switch A operated Switch B to OFF before operating point Switch B to OFF locks Brake pedal depressed Clutch pedal depressed
N23-0199
Display field 2 000011 001011 000111 000001 000000 010011 100011
Display groups 004 through 011 at full load

Note Accelerate vehicle at full throttle before inspecting. The measured values must be read off or printed out once an engine speed of 3000 rpm is reached (2nd person required). Pay attention to safety precautions for test drives Chapter 23-1.
Display group 004 under full load (test drive in 2nd gear coolant temperature not below 75C)
Read measured value block 4 xxx rpm 1 xx.x b. TDC 2 xx.x KW 3 x.xx KW 4 < Display field Synchronizing angle Fuel delivery duration (set value) Commencement of injection (set value) Engine speed Specification -5...4 KW 1923 KW 16 BTDC23 BTDC 28003200 rpm Analysis ---------
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Display group 008 under full load (test drive in 2nd gear coolant temperature not below 75C)
Read measured value block 8 xxx rpm 1 xx.x mg/s 2 xx.x mg/s 3 xx.x mg/s 4 < Display field Injection rate limit based on drawn in air mass (smoke prevention) Injection rate limit based on engine speed (torque limit) Injection rate (driver's instruction) Engine speed Specification 44,052.0 mg/s Analysis 01-4 page 11 01-4 page 11 01-4 page 11 ---
39,044.0 mg/s 42,052.0 mg/s 28003200 rpm
Analysis: Display group 008, display field 2 - Injection rate (driver's instruction)
Readout on -V.A.G 1552below 42.0 mg/s
Rectifying fault
Repeat test at full throttle. Test accelerator pedal position sender -G79- Current Flow Diagrams,
Analysis: Display group 008, display field 3 - Injection rate limit over engine speed
Readout on -V.A.G 1552below 39.0 mg/s
Rectifying fault
Read off set value at 3000 rpm.
Analysis: Display group 008, display field 4 - Injection rate limit (smoke prevention)
Readout on -V.A.G 1552below 44.0 mg/s ing and Fitting Locations.
Rectifying fault
Test air mass meter -G70- Current Flow Diagrams, Electrical Fault Find Test exhaust gas recirculation Chap. 23-4.
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Display group 011 under full load (test drive in 2nd gear coolant temperature not below 75 C)
Read measured value block 11 xxx rpm 1 xxxx mbar 2 xxxx mbar 3 xxx % 4 < Display field On/off ratio (actuation) of solenoid valve for charge pressure control -N75Charge pressure (actual value) Charge pressure (specified value) Engine speed Specification 55...80% Analysis 01-4 page 12 01-4 page 12 ----< Readout on display
1850...2250 mbar 1900...2100 mbar 2800...3200 rpm
Analysis: Display group 011, display field 3 - Charge pressure (actual value)
Readout on -V.A.G 1552below 1850 mbar
Possible cause of fault Charge pressure control defective Leaking intake manifold Damaged turbocharger
Rectifying fault
Inspecting charge pressure control 1.9/

74 TDI Engine, Mechanics; Rep. Gr. 21.
Analysis: Display group 011, display field 4 - On/off ratio (actuation) of solenoid valve for charge pressure control -N75-
Readout on -V.A.G 1552below 55 % above 80 %
Possible cause of fault Charge pressure control defective Charge pressure is not controlled
Rectifying fault
Inspecting charge pressure control 1.9/

74 TDI Engine, Mechanics; Rep. Gr. 21.
Display group 125 - CAN databus

Display group 125 with ignition switched on
Read measured value block 125 ABS 1 1 2 Combi 1 3 Airbag 1 4 < Display field Airbag control unit Dash panel insert CU ABS control unit not assigned Specification Airbag 1 Combi 1 ABS 1 --Analysis 01-4 page 13 01-4 page 13 01-4 page 13 ---
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Analysis: Display group 125, display field 2, 3 or 4
Readout on -V.A.G 1552ABS 0 Combi 0 Airbag 0
Rectifying fault
Test CAN databus Chap. 23-6.
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OCTAVIA 1997
1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
23
23-4
Testing exhaust gas recirculation
Connection diagram for vacuum hoses

1 - Vacuum unit s for throttle valve 2 - Changeover valve for intake manifold flap -N239s desired resistance: 25...45 Y 3 - Distributor part 4 - Non-return valve s For vehicles 03.02 s white connection points to charge pressure control solenoid valve / to vacuum unit / to switchover valve 5 - Vacuum unit 6 - To air filter 7 - Solenoid valve for charge pressure control -N75s desired resistance: 14...20 Y 8 - Vacuum setting element s for charge pressure control s part of turbocharger, cannot be replaced separately 9 - Exhaust gas recirculation solenoid valve -N18s desired resistance: 14...20 Y 10 - Mechanical exhaust gas recirculation valve 11 - Tandem pump 12 - Brake servo unit 13 - Distributor part s with non-return valve for brake servo unit
6 13
12
11
10
8
S20-0123

Test sequence
The exhaust gas recirculation function is checked in function 04 (basic setting). As a result of this procedure the exhaust gas recirculation valve is pulsed every 10 seconds, so that the extreme values for the exhaust gas recirculation (air mass meter) can be read off in measured value block 003 in display field 3.
Edition 04.03 S00.5139.51.20
23-4 page 1
23
OCTAVIA 1997
1.9 l/74 kW (TDI) Engine, Fuel Injection and Glow Plug System
Connect vehicle system tester -V.A.G 1552-. Start engine and select address word 01 Engine electronics Chapter 01-1.
Enter function 04 basic setting and select display

group number number 003. Note After selecting display group number 003 and confirming with Q , the idling speed is increased by the engine control unit in display field 1 to 13801420 rpm. Readout on display: The display in display field 2 must switch between EGR not active and EGR active every 10 seconds. The readouts in display field 3 and 4 must vary within the following control range: Note If a constant value of 539 mg/H and higher is shown in display field 3, test the air mass meter. EGR not active: Specified value display field 3: 410600 mg/stroke nominal value, display field 4: 1822 % EGR active: Specified value display field 3: 160310 mg/stroke nominal value, display field 4: 6367 % If the specified values are not reached:
System in basic setting 3 -> 1400 rpm EGR not active 500 mg/H 20 %
Test mechanical exhaust gas recirculation valve
1.9 l/74 kW (TDI) Engine, Mechanical Components; Rep. Gr. 26. 23-4 page 1. 01-1.
Inspect the connection diagram for the vacuum hoses Test exhaust gas recirculation valve -N18- Chap.
23-4 page 2
Edition 04.03 S00.5139.51.20
OCTAVIA 1997
23
23-5
Engine control unit
Testing voltage supply for engine control unit

Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3CHand multimeter (e.g. -V.A.G 1526 A-) Adapter cable set (e.g. -V.A.G 1594 C-) Test box -V.A.G 1598/31-
Test conditions
Fuses o.k. Battery voltage at least 11.5 volts Generator o.k.

Test sequence
Connect vehicle system tester -V.A.G 1552-. Switch

ignition on and select address word 01 Engine electronics Chap. 01-1.
Enter function 08 read measured value block and

select display group 012. Readout on display:
Reading measured value block 11111111 0.00 12.5 V 12 -> 28.5 C
Read off value indicated in display field 3.

Specified value: approx. battery voltage (constant)

Q.
If the value displayed fluctuates or if the battery voltage is not reached:
Switch off ignition. Connect test box -V.A.G 1598/31- to the wiring loom
of the engine control unit Chap. 23-3.
Connect handheld multimeter as follows:

Test box - V.A.G 1598/ 31-, bush 1, 2 + 4, 5 37 + 4, 5 Specification approx. 0 V approx. 0 V
Switch on ignition. Measure once again the voltage between the bushes.
Edition 12.03 S00.5139.52.20
Engine control unit
23-5 page 1
23
Test box - V.A.G 1598/ 31-, bush 1, 2 + 4, 5 37 + 4, 5
OCTAVIA 1997
Specification approx. battery voltage approx. battery voltage
If the specified values are not reached:
Test diesel direct injection system relay - J322-.
Replacing diesel direct injection system control unit -J248Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1. The vehicle system tester -V.A.G 1552 - displays the control unit identification, e. g.:
038906019R 1.9l R4 Coding 00003 EDC G000SG 1053 -> WSC XXXXX
Note Part No. of control unit and coding. Enter function 06 End output and confirm entry with
Q.
Switch off ignition. Remove the cooling water tank cover Body Work;
Rep. Gr. 66.
Release the connector catches and unplug the connectors of the diesel direct injection control unit - J248-.
Use a screwdriver to push the catch of the fixture to

the side and pull out the engine control unit forward.
Insert new engine control unit.

After installing the diesel direct injection system control unit -J248-, it is then necessary to carry out the following steps:
Perform coding of diesel direct injection system control unit -J248- 23-5 page 3.
Adapt new diesel direct injection system control unit On vehicles fitted with CCS: Activate CCS 23-5
page 4.
-J248- to immobiliser control unit Electrical System; Rep. Gr. 96.

A23-0026
Interrogate fault memory of new engine control unit

and erase fault memory, rectify any faults present Chap. 01-1. For vehicles from 08.03
23-5 page 2
Engine control unit
Edition 12.03 S00.5139.52.20
OCTAVIA 1997
23
Generate readiness code Chapter 01-3.

For all vehicles
Perform a test drive.

Note Pay attention to safety precautions during the test drive Chap. 23-1.
Once again interrogate the fault memory of the diesel

direct injection system control unit - J248-.
Coding diesel direct injection system control unit -J248If the code displayed does not match the vehicle or if the diesel direct injection system control unit -J248- has been replaced, it is then necessary to code the control unit as follows. Special tools, test and measuring equipment and auxiliary items required Vehicle system tester -V.A.G 1552- with cable -V.A.G 1551/3, 3A, 3B oder 3C-
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1.
Enter function 07 Code control unit.

Readout on display:
Coding control unit Enter code number xxxxx (0 -32767) Q.
Enter code number by referring to table of codes and

confirm entry with Table of codes: Control unit identification 038 906 019 R 038 906 019 FJ 038 906 019 DL 038 906 019 KH Variant Manual gearbox for 4x4 models Code number 00003
The vehicle system tester -V.A.G 1552 - displays the control unit identification, e. g.:
038906019R 1.9l R4 Coding 00003
EDC G000SG 1053 -> WSC XXXXX

Q.
Switch ignition off and on again.

Note The entered coding is activated by switching the ignition on and off again.
Edition 12.03 S00.5139.52.20
Engine control unit
23-5 page 3
23
OCTAVIA 1997
Activating and deactivating cruise control system (CCS)

Test condition
No fault in fault memory, interrogating fault memory

Chap. 01-1
Procedure

ignition on and select address word 01 Engine electronics Chap. 01-1. Readout on display, e.g.: If G000SG is displayed, the cruise control system is active Readout on display: If 000SG is displayed, the cruise control system is not active
038906019R 1.9l R4 Coding 00003 EDC 000SG 1053 -> WSC XXXXX 038906019R 1.9l R4 Coding 00003 EDC G000SG 1053 -> WSC XXXXX
Press . Select function 11 login procedure.

Readout on display:
Login procedure Enter code number XXXXX
Enter code number as specified in table.

Code number 11463 16167 Cruise control system (CCS) Activate CCS Deactivate CCS
Confirm the entry with Q . Enter function 06 End output and confirm entry with
Q.
After the CCS is activated, conduct a test drive as an operational check.
23-5 page 4
Engine control unit
Edition 12.03 S00.5139.52.20

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OCTAVIA 1997
28
28 Glow Plug System

28-1 Testing preheating system
Check for proper operation

Special tools, test and measuring equipment and aids required
Hand multimeter (e.g. -V.A.G 1526 A-) Current flow diagram
Test conditions
Battery voltage at least 11.5 volts Diesel direct injection system control unit -J248 - O.K. Fuses in fuse holder on battery are O.K.
Test sequence
Switch off ignition. Remove engine cover.

To do so remove the front and rear engine cover upwards with a sudden motion.
Disconnect plug -1- from Coolant temperature sender

(-G62-) -2-. Note By disconnecting the plug from the coolant temperature sender, engine condition cold is simulated and when the ignition is switched on a corresponding preheating process is performed.
2 1
2 1
Remove glow plug connectors from the glow plugs. Connect Hand multimeter for voltage measurement to
a glow plug connector and engine mass.
Switch on ignition. The approx. battery voltage must

be displayed for approximately 20 seconds. If no voltage is present:
S23-0119
If necessary eliminate wire interruption or short-circuit.

Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
During the simulated preheating process the glow period warning lamp -K29- must light up. If the warning lamp does not light up:
Testing Glow period warning lamp - K29 - Current

Flow Diagrams, Fault Finding Electrics and Fitting Locations.
Edition 12.03 S00.5139.52.20
Testing preheating system
28-1 page 1
28
Checking glow plugs
OCTAVIA 1997
Special tools, test and measuring equipment and aids required

Diode test lamp (e.g. -V.A.G 1527 B-) Flexible-head wrench for glow plugs (e.g. -3220-)
Test condition
Battery voltage at least 11.5 volts

Test sequence
Switch off ignition. Remove engine cover.

To do so remove the front and rear engine cover upwards with a sudden motion.
Remove glow plug connectors from the glow plugs. Connect the wire of the diode test lamp to battery positive (+).
Apply test prod of the diode test lamp to each glow

plug in turn. If the diode lights up: Glow plug is O.K. If the diode does not light up:
Replace glow plug. If necessary remove and install glow plugs with flexible-head wrench (e.g. -3220-). Tightening torque: 15 Nm
S28-0118
28-1 page 2
Testing preheating system
Edition 12.03 S00.5139.52.20

Manual Skoda Octavia 1,9 74kW ATD

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1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

List of Supplements to Workshop Manual

Edition 03.01 04.03 12.03

Article Number S00.5139.50.20 S00.5139.51.20 S00.5139.52.20

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

23 Fuel Formation, Injection

28 Glow Plug System

Edition 12.03 S00.5139.52.20

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Properties of the self-diagnosis

Technical data of self-diagnosis

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Engine idling yes yes yes yes yes yes no yes no

Normal driving yes yes no no yes yes no yes no

V.A.G 1552 V.A.G 1551/3

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Operate the vehicle system tester by referring to the

Vehicle system test Enter address word XX

Enter address word 01 Engine electronics and confirm entry with

Interrogating and erasing fault memory

Interrogating fault memory

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Only if the engine does not start:

Enter function 06 End output and confirm entry with

If one or several faults are stored:

. -> Fault number: 16685 P0301 044

Readout on display, e.g.:

. Cylinder 1 Combustion misfiring detected ->

Fault source and fault type appear in the display, e.g.:

The stored faults are displayed in sequence.

Enter function 06 End output and confirm entry with

Enter function 00 for Automatic test sequence and

Erasing fault memory

Fault eliminated Fault memory interrogated 01-1 page 3

Enter function 05 Erase fault memory and confirm

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Enter function 06 End output and confirm entry with

Perform a test drive. Then, once again interrogate the

Fuses must be OK in compliance with the current flow

Enter function 03 Final control diagnosis.

Edition 12.03 S00.5139.52.20

1.9/74 kW (TDI) Engine, Fuel Injection and Glow Plug System

Actuator diagnosis Exhaust gas recirculation valve -N18

Testing Exhaust gas recirculation valve -N18 Chap. 23-1.

Disregard display. Press

Test charge pressure control solenoid valve -N75 Chap. 23-1.

Switch off ignition. Inspecting Intake manifold flap change-over valve

Continue final control diagnosis with the engine off

. Actuator diagnosis Glow period warning lamp -K29 ->

Test glow period warning light - K29 - Electrical

. Actuator diagnosis Radiator fan control ->

Edition 12.03 S00.5139.52.20

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